CN108526469B - Composite for metal powder injection molding, molded body, sintered body, and method for producing same - Google Patents

Abstract

The invention relates to a composite for metal powder injection molding, a molded body, a sintered body and a manufacturing method. The composite for metal powder injection molding is characterized by comprising: secondary particles, wherein the first metal particles are bonded to each other; and a matrix region including second metal particles of a different constituent material from the first metal particles and a binder. Preferably, the secondary particles are formed by bonding the first metal particles to each other via a binder. Preferably, the average particle diameter of the second metal particles is smaller than the average particle diameter of the first metal particles.

Description

Composite for metal powder injection molding, formed body, sintered body, and production method

technical field

The present invention relates to a composite for metal powder injection molding, a metal powder molded body, a method for producing a sintered body, and a sintered body.

Background technique

As a method of molding metal powder, a compression molding method is known, which obtains a molded body of a predetermined shape by filling a predetermined molding die with granulated powder containing a metal powder and an organic binder and compressing it. The obtained molded body is subjected to a degreasing treatment to remove the organic binder and a firing treatment of the sintered metal powder to obtain a metal sintered body. This technique is a type of powder metallurgy technique and can mass-produce a metal sintered body of a complex shape according to the shape of a molding die, and thus has been popularized in many industrial fields in recent years.

For example, Patent Document 1 discloses a metal powder injection molding method in which a molding material obtained by mixing metal powder and a binder is injected into a mold to shape a molded body, and then the molded body is heated and removed The binder is then sintered. Furthermore, it has been disclosed that the mixing ratio when the metal powder and the binder are mixed to prepare the composite is set to 60:40.

Patent Document 1: Japanese Patent Laid-Open No. 2001-152205

In recent years, metal sintered bodies have been required not only to have high strength peculiar to metal materials, but also to have properties such as high ductility and high toughness. That is, it is required to realize a metal sintered body having a plurality of different properties that generally have opposing tendencies.

However, existing metal sintered bodies cannot sufficiently satisfy such market demands.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a sintered body having various properties, a sintered body production method capable of producing such a sintered body, a composite for metal powder injection molding, and a metal powder molded body.

The above objects are achieved by the present invention described below.

The composite for metal powder injection molding of the present invention is characterized by having: secondary particles in which the first metal particles are bonded to each other (Japanese expression: bond); and a matrix region including the second metal A particle and a binder, the constituent material of the second metal particle is different from the constituent material of the first metal particle.

Thereby, a composite for metal powder injection molding capable of producing a sintered body having various properties can be obtained.

In the composite for metal powder injection molding of the present invention, preferably, the constituent material of the first metal particles is any one of Fe-based alloys, Ni-based alloys, and Co-based alloys.

Thereby, a sintered body having high mechanical strength can be realized.

In the composite for metal powder injection molding of the present invention, preferably, the secondary particles are formed by bonding the first metal particles to each other via a binder.

Thereby, since the first metal particles are bonded to each other by the adhesiveness of the binder, secondary particles that are less prone to distortion can be obtained irrespective of the constituent material of the first metal particles.

In the composite for metal powder injection molding of the present invention, preferably, in the secondary particles, the first metal particles are mutually self-adhesive (Japanese expression: fixation).

Thereby, the usage-amount of a binder can be reduced or a binder can not be used at all, so that the shrinkage rate of the molded object obtained by injection-molding a compound can be further reduced.

In the composite for metal powder injection molding of the present invention, preferably, the secondary particles are dispersed in the matrix region.

Thereby, a homogeneous complex can be obtained. Such a composite can produce a homogeneous molded body with little deformation, and finally a sintered body with high dimensional accuracy and high mechanical strength can be realized.

In the composite for metal powder injection molding of the present invention, preferably, the average particle diameter of the second metal particles is smaller than the average particle diameter of the first metal particles.

As a result, depending on the size relationship between the particle sizes of the metal particles, it is easy to obtain a structure in which a region with a small average crystal grain size is surrounded by a region with a large average crystal grain size, so that both high mechanical strength and high ductility can be achieved. A composite for metal powder injection molding of a sintered body.

The metal powder compact of the present invention is characterized by having: secondary particles in which first metal particles are bonded to each other; and a matrix region including second metal particles and a binder, the second The constituent material of the metal particles is different from the constituent material of the first metal particles.

Thereby, a metal powder compact capable of producing a sintered body having various different properties can be obtained.

The method for producing a sintered body of the present invention is characterized by comprising: a step of injecting the composite for metal powder injection molding of the present invention into a molding die to obtain a molded body; and a step of firing the molded body to obtain a sintered body. process.

Thereby, a sintered body having various different properties can be produced.

The sintered body of the present invention is characterized by having: a first part including a sintered body of first metal particles; and a second part surrounding the first part and including a second metal having a constituent material different from that of the first metal particles agglomerates of particles.

Thereby, a sintered body having various different properties can be obtained.

In the sintered body of the present invention, preferably, the average crystal grain size of the second portion is smaller than the average crystal grain size of the first portion.

Thereby, in the sintered body, a structure is formed in which the second portion with a relatively small particle size expands so as to surround the first portion with a relatively large particle size. In such a structure, it is considered that high mechanical strength is obtained mainly by the second part, and high ductility is mainly obtained by the first part. Therefore, the sintered body can have both high mechanical strength and high ductility.

Description of drawings

FIG. 1 is a cross-sectional view showing an embodiment of the composite for metal powder injection molding of the present invention.

FIG. 2 is an enlarged view of part A of FIG. 1 .

3 is a cross-sectional view showing an embodiment of the sintered body of the present invention.

4 is a cross-sectional view showing an embodiment of the metal powder compact of the present invention.

FIG. 5 is an enlarged view of part B of FIG. 4 .

Symbol Description

1 composite, 2 secondary particles, 3 matrix regions, 5 molded body, 21 first metal particles, 22 binder, 30 granulated particles, 31 second metal particles, 32 binder, 100 sintered body, 110 first metal particles One, 111 crystal structure, 120 second part, 121 crystal structure

Detailed ways

Hereinafter, the composite for metal powder injection molding, the metal powder molded body, the manufacturing method of the sintered body, and the sintered body of the present invention will be described in detail based on the preferred embodiments shown in the drawings.

Compounds for Metal Powder Injection Molding

First, an embodiment of the composite for metal powder injection molding of the present invention will be described.

The composite for metal powder injection molding (hereinafter also simply referred to as "composite") according to the present embodiment contains metal powder and a binder as a molding material for the metal powder injection molding method.

FIG. 1 is a cross-sectional view showing an embodiment of the composite for metal powder injection molding of the present invention, and FIG. 2 is an enlarged view of a portion A in FIG. 1 .

The composite 1 shown in FIGS. 1 and 2 has: secondary particles 2 in which first metal particles 21 are bound to each other; and a matrix region 3 including a constituent material different from that of the first metal particles 21 The second metal particles 31 and the binder 32 .

In addition, in the secondary particles 2 shown in FIG. 2 , the first metal particles 21 are bonded to each other via the binder 22 .

In addition, the secondary particle 2 refers to a particle in which a plurality of first metal particles 21 as primary particles are aggregated. Therefore, the method of bonding the first metal particles 21 to each other is not particularly limited, and may be bonded via an intermediate other than the binder 22 (eg, a coupling agent or the like).

On the other hand, in the matrix region 3 shown in FIG. 2 , the plurality of second metal particles 31 are dispersed in the binder 32 . In addition, in this invention, the area|region distributed around the secondary particle 2 is called the matrix area|region 3.

By having such secondary particles 2 and matrix regions 3 , the sintered body of the second metal particles 31 is easily distributed on the surface side in a sintered body obtained by firing them. Therefore, for example, when a material with high corrosion resistance is used as the constituent material of the second metal particles 31 , the corrosion resistance is also dominant in the sintered body.

On the other hand, when a material having a higher mechanical strength than the second metal particles 31 is used as the constituent material of the first metal particles 21 , compared with the case where the sintered body is composed of only the sintered body of the second metal particles 31 , the Improve the mechanical strength of the sintered body.

Therefore, by appropriately selecting the constituent material, it is possible to coexist a plurality of properties that are difficult to have in a single constituent material, such as high mechanical strength and high corrosion resistance. Therefore, the composite 1 having the secondary particles 2 and the matrix region 3 can realize a sintered body in which such a plurality of different characteristics coexist.

In addition, although the average particle diameter of the second metal particles 31 may be larger than the average particle diameter of the first metal particles 21 , it is preferably set to be smaller than the average particle diameter of the first metal particles 21 . By making the composite 1 in such a form, the aggregate of the first metal particles 21 is surrounded by the second metal particles 31 having a smaller average particle diameter than the first metal particles 21 . The composite 1 in this form is injected into a molding die to form a molded body, and then fired to form a sintered body. In such a sintered body, a region with a relatively small crystal grain size is formed surrounded by a relatively large crystal grain size. shape of the area. Therefore, although there are some variations depending on the combination of the constituent materials of the first metal particles 21 and the constituent materials of the second metal particles 31 , in general, the sintered body can have both high mechanical strength and high ductility. This is because the crystal grain size affects both mechanical strength and ductility. Generally speaking, there is a tendency as follows: as the crystal grain size becomes smaller, the mechanical strength becomes higher and the ductility becomes lower; as the crystal particle size becomes larger Mechanical strength becomes lower and ductility becomes higher.

On the other hand, the composite 1 as described above exhibited good properties not only as a sintered body but also as a composite.

For example, when the particulate secondary particles 2 are present inside the matrix region 3 , the shape retention of the composite 1 can be easily maintained. Therefore, even if the content rate of the binder 32 in the matrix region 3 is reduced, deformation of the molded body obtained by injection molding the composite 1 can be suppressed, and a sintered body with high dimensional accuracy can be finally obtained.

The presence ratio of the secondary particles 2 in the composite 1 is not particularly limited, but is preferably 1% or more and 99% or less, more preferably 10% or more and 97% or less, still more preferably 30% or more and 96% or less, and particularly preferably Above 60% and below 95%. Thereby, the balance between the secondary particles 2 and the matrix region 3 is further optimized, so that a high mechanical strength can be obtained in the sintered body. At the same time, a sintered body having both the properties of the constituent material of the first metal particles 21 and the properties of the constituent material of the second metal particles 31 at a higher level can be obtained.

In addition, this existence ratio was calculated|required by calculating the ratio of the area occupied by the secondary particle 2 in the cross section of the composite 1 .

In addition, the secondary particles 2 are preferably dispersed in the matrix region 3 . Thus, a homogeneous composite 1 can be obtained. Such a composite 1 can produce a homogeneous molded body with little deformation, and can finally realize a sintered body with high dimensional accuracy and high mechanical strength.

secondary particles

The secondary particles 2 shown in FIG. 2 include a plurality of first metal particles 21 and a binder 22 .

The secondary particles 2 are granular as described above, but from the viewpoint of the aspect ratio, the average value of the major axis/minor axis is preferably 1 or more and 3 or less, more preferably 1 or more and 2.5 or less, and still more preferably 1 or more and 2 or less. Since the secondary particles 2 having such an aspect ratio are highly isotropic in shape, breakage or the like is unlikely to occur. Therefore, the secondary particles 2 can serve as the skeleton of the composite 1, and the shape retention properties of the molded body obtained by molding the composite 1 can be further improved.

It should be noted that the aspect ratio of the secondary particles 2 is obtained, for example, by acquiring an electron microscope observation image of the cross section of the composite 1, and obtaining the maximum length (major axis) of the secondary particle 2 and the maximum value in the direction orthogonal thereto on the image. Length (minor diameter) is calculated. In addition, when calculating an average value, 10 or more pieces of data are used. In addition, the outline of the secondary particle 2 may be easily recognized by using the element distribution image as needed.

The average diameter of the secondary particles 2 is preferably 1.5 times or more and 100 times or less the average particle diameter of the first metal particles 21 , more preferably 2 times or more and 80 times or less, and still more preferably 3 times or more and 50 times or less. . Thereby, the balance between the particle diameter of the secondary particles 2 and the particle diameter of the first metal particles 21 is optimized. As a result, the secondary particles 2 themselves are more difficult to deform, and the shape retention properties of the molded body obtained by molding the composite 1 can be further improved.

It should be noted that the average diameter of the secondary particles 2 is, for example, the diameter of a perfect circle (equivalent circle diameter) having the same area as the cross-section of the secondary particle 2 on the image obtained by taking an electron microscope observation image of the cross-section of the composite 1 . ) to find out. In addition, when calculating an average value, 10 or more pieces of data are used. In addition, the outline of the secondary particle 2 may be easily recognized by using an element map image as needed.

first metal particle

The constituent material of the first metal particles 21 is not particularly limited, for example, Mg, Al, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Pd, Simple metals such as Ag, In, Sn, Ta, and W, or alloys and intermetallic compounds containing at least one of them.

In addition, the secondary particles 2 may contain other metal particles and ceramic particles composed of a material different from that of the first metal particles 21 . The addition amount of these other metal particles and ceramic particles is preferably 50% by volume or less, more preferably 30% by volume or less, and even more preferably 10% by volume or less of the first metal particles 21 .

In addition, among the above-mentioned alloys, examples of Fe-based alloys include stainless steel, low-carbon steel, carbon steel, heat-resistant steel, die steel, high-speed tool steel, alloy steel for machine structures, and Fe—Ni. Alloys, Fe-based alloys like Fe-Ni-Co alloys.

In addition, examples of Ni-based alloys include Ni-Cr-Fe-based alloys, Ni-Cr-Mo-based alloys, and Ni-based alloys such as Ni-Fe-based alloys, and specifically, Ni-32Mo -15Cr-3Si, Ni-16Mo-16Cr-4W-5Fe, Ni-21Cr-9Mo-4Nb, Ni-20Cr-2Ti-1Al, Ni-19Cr-12Co-6Mo-1W-3Ti-2Al, etc.

In addition, examples of Co-based alloys include Co-Cr-based alloys, Co-Cr-Mo-based alloys, and Co-based alloys such as Co-Al-W-based alloys.

In addition, examples of Ti-based alloys include alloys of Ti and metal elements such as Al, V, Nb, Zr, Ta, and Mo, and specific examples include Ti-6Al-4V, Ti-6Al-7Nb Wait.

In addition, examples of Al-based alloys include duralumin and the like.

Among them, the constituent material of the first metal particles 21 is preferably any one of Fe-based alloys, Ni-based alloys, and Co-based alloys. Such a constituent material is useful as a constituent material of the first metal particles 21 because a sintered body having high mechanical strength can be realized.

In addition, examples of the ceramic material constituting the ceramic particles include alumina, magnesia, beryllium oxide, zirconia, yttria, forsterite, talc, wollastonite, mullite, cordierite, and ferrite. , silicon aluminum oxynitride polymer materials, cerium oxide-like oxide ceramic materials; silicon nitride, aluminum nitride, boron nitride, titanium nitride, silicon carbide, boron carbide, titanium carbide, tungsten carbide-like non-oxides Department of ceramic materials, etc.

The average particle diameter of the first metal particles 21 is preferably 1 μm or more and 30 μm or less, more preferably 3 μm or more and 25 μm or less, and further preferably 5 μm or more and 20 μm or less. Since the first metal particles 21 having such a particle size are easy to form the secondary particles 2 , they contribute to the realization of the stable secondary particles 2 . In addition, when the composite 1 is fired, crystals having a relatively large particle size are easily formed in the sintered product of the secondary particles 2, which contributes to the improvement of the ductility of the sintered body.

It should be noted that, when the average particle diameter of the first metal particles 21 is smaller than the lower limit value, depending on the content of the binder 22, etc., the secondary particles 2 may be easily deformed, and the composite may not be sufficiently improved. 1 The ductility of the sintered body obtained by firing. On the other hand, when the average particle diameter of the first metal particles 21 exceeds the upper limit, it may be difficult to form the particulate secondary particles 2 , depending on the content of the binder 22 and the like. It is easy to generate voids in the sintered material, and it becomes difficult to sufficiently improve the mechanical strength.

It should be noted that when a perfect circle having the same area as the first metal particles 21 is assumed in the cross section of the composite 1, the particle diameter of the first metal particles 21 is obtained as the diameter of the perfect circle (equivalent circle diameter) . In addition, when the circle-equivalent diameter is determined for 10 or more randomly selected first metal particles 21, the average particle diameter is the average value.

In addition, for the first metal particles 21, the particle diameter when the accumulation of the particle size based on mass in the particle size distribution obtained by the laser diffraction method is 10% from the small diameter side is D10, and the particle diameter when it reaches 50% is D10. When D50 and the particle diameter at 90% are set as D90, (D90-D10)/D50 is preferably 0.5 or more and 5 or less, and more preferably 1.0 or more and 3.5 or less. The first metal particles 21 satisfying such conditions can contribute to the realization of more stable secondary particles 2, and can achieve both the mechanical strength and the ductility of the finally obtained sintered body.

Such first metal particles 21 may be produced by any method. For example, atomization methods (water atomization method, gas atomization method, high-speed rotating water atomization method, etc.), reduction method, carbonyl method, pulverization method, etc. can be used. particles produced by the method.

Among them, the first metal particles 21 are preferably produced by an atomization method. According to the atomization method, the difference in particle size is small, and a metal powder with a uniform particle size can be obtained. Therefore, by using such first metal particles 21 , stable secondary particles 2 are realized, and the secondary particles 2 in the composite 1 serve as good frameworks. Therefore, the molded body obtained by molding the composite 1 is excellent in shape retention, and the dimensional accuracy of the sintered body can be improved. That is, it contributes to the realization of a sintered body having improved mechanical strength while having a plurality of different properties.

It should be noted that the content of the first metal particles 21 in the secondary particles 2 is not particularly limited, but is preferably 60 vol% or more and 99 vol% or less, more preferably 70 vol% or more and 97 vol% or less, still more preferably It is 80 volume% or more and 95 volume% or less. Setting the content of the first metal particles 21 within the aforementioned range contributes to the realization of stable secondary particles 2 , and since the amount of the binder 22 is not easily depleted, the secondary particles 2 are not easily deformed.

adhesive

The binder 22 binds the first metal particles 21 to each other (the same applies to other metal particles and ceramic particles) to facilitate the formation of the secondary particles 2 . The binder 22 is almost removed in the firing step.

That is, the secondary particles 2 are formed by bonding the first metal particles 21 to each other via the binder 22 . In such secondary particles 2 , since the first metal particles 21 are bonded to each other by the adhesiveness of the binder 22 , secondary particles that are less prone to distortion can be obtained irrespective of the constituent material of the first metal particles 21 and the like. particle 2.

The adhesive 22 is not particularly limited as long as it has binding properties, and examples thereof include polyolefins such as polyethylene, polypropylene, and ethylene-vinyl acetate copolymer, polymethyl methacrylate, polyolefin, etc. Acrylic resins such as butyl methacrylate, styrene resins such as polystyrene, polyvinyl chloride, polyvinylidene chloride, polyamide, polyethylene terephthalate, polybutylene terephthalate Various resins such as polyesters, polyethers, polyvinyl alcohol, polyvinylpyrrolidone or their copolymers, waxes, alcohols, higher fatty acids, fatty acid metals, higher fatty acid esters, higher fatty acid amides, nonionic surfactants Agents, silicone-based lubricants, etc., use one or a mixture of two or more of them.

Among them, examples of waxes include vegetable waxes such as candelilla wax, carnauba wax, rice bran wax, Japanese wax, and jojoba wax, animal waxes such as beeswax, lanolin, and spermaceti, and Mineral waxes such as montan wax, ozokerite, ceresin, natural waxes such as paraffin wax, microcrystalline wax, petroleum waxes such as petrolatum, synthetic hydrocarbons such as polyethylene wax, montan wax derivatives, paraffin derivatives, modified waxes such as microcrystalline wax derivatives, hydrogenated waxes such as hydrogenated castor oil, hydrogenated castor oil derivatives, fatty acids such as 12-hydroxystearic acid, and stearic acid amides amides, esters such as phthalic anhydride imides, and other synthetic waxes.

Moreover, as an alcohol, a polyhydric alcohol, polyethylene glycol, polyglycerol etc. are mentioned, for example, Cetyl alcohol, stearyl alcohol, oleyl alcohol, mannitol, etc. are used especially preferably.

Moreover, as a higher fatty acid, a stearic acid, an oleic acid, a linoleic acid etc. are mentioned, for example, Especially saturated fatty acid, such as lauric acid, myristic acid, palmitic acid, stearic acid, and arachidic acid, is used.

In addition, as fatty acid metal, for example, lauric acid, stearic acid, succinic acid, stearoyl lactic acid, lactic acid, phthalic acid, benzoic acid, hydroxystearic acid, ricinoleic acid, naphthenic acid, oil Compounds of higher fatty acids such as acid, palmitic acid, and erucic acid and metals such as Li, Na, Mg, Ca, Sr, Ba, Zn, Cd, Al, Sn, Pb, and Cd, especially magnesium stearate, Calcium stearate, sodium stearate, zinc stearate, calcium oleate, zinc oleate, magnesium oleate, etc.

Moreover, as a nonionic surfactant, Electrostripper TS-2, Electrostripper TS-3 (both by Kao Corporation) etc. are mentioned, for example.

In addition, as the silicone-based lubricant, for example, dimethylpolysiloxane and modified products thereof, carboxyl group-modified silicone, α-methylstyrene-modified silicone, and α-olefin-modified silicone can be mentioned. , polyether modified silicone, fluorine modified silicone, hydrophilic special modified silicone, olefin polyether modified silicone, epoxy modified silicone, amino modified silicone, amide modified silicone, Alcohol-modified silicone, etc.

Note that, as the binder 22, it is particularly preferable to contain polyvinyl alcohol or polyvinylpyrrolidone. Since these binder components have high binding properties, the secondary particles 2 can be efficiently formed even in relatively small amounts. In addition, since the thermal decomposability is also high, it can be decomposed and removed reliably in a short time when degreasing and firing are performed.

The content of the binder 22 in the secondary particles 2 is not particularly limited, but is preferably 1% by volume or more and 40% by volume or less, more preferably 3% by volume or more and 30% by volume or less, and even more preferably 5% by volume or more and 20% by volume. volume % or less. By setting the content of the binder 22 within the above-mentioned range, it contributes to the realization of stable secondary particles 2, and the amount of the binder 22 is not excessive, thereby contributing to the increase in the density of the sintered body and Improve mechanical strength.

In addition, when the content rate of the binder 22 is less than the said lower limit, there exists a possibility that the secondary particle 2 may become misshapen easily by the particle diameter etc. of the 1st metal particle 21. On the other hand, when the content rate of the binder 22 exceeds the above-mentioned upper limit, the amount of the binder 22 is excessive, and it may be difficult to increase the density of the sintered body, or the shrinkage rate may increase, and the dimensional accuracy of the sintered body may easily decrease.

In addition, the content rate of the binder in the secondary particle 2 can be calculated|required from the area ratio of the binder 22 in the cross section of the secondary particle 2, for example by observing the cross section.

In addition, components other than the first metal particles 21 and the binder 22 , for example, various additives such as a solvent (dispersion medium), a rust inhibitor, an antioxidant, a dispersant, and an antifoaming agent may be added to the secondary particles 2 . The addition amount of these additives is preferably about 5% by mass or less of the secondary particles 2, and more preferably about 3% by mass or less.

In addition, the binder 22 may be added as needed. For example, when the first metal particles 21 are spontaneously bonded by self-adhesion or the like, the addition of the binder 22 can be omitted. That is, among the secondary particles 2, the first metal particles 21 may self-adhere to each other. As a result, the amount of the binder 22 to be used can be reduced or the binder 22 can be completely eliminated, so that the shrinkage rate of the molded body obtained by injection-molding the composite 1 can be further reduced.

In addition, self-adhesion (adhere; adhering (Japanese expression)) refers to the state in which the surfaces of the first metal particles 21 directly contact each other and are integrated while maintaining the mutual particle shape.

In addition, the self-adhesive first metal particles 21 and the non-self-adhesive first metal particles 21 may be mixed in the secondary particles 2 .

stromal area

The matrix region 3 shown in FIG. 2 includes second metal particles 31 and a binder 32 . Compared with the first metal particles 21 , the second metal particles 31 have different constituent materials and have a smaller average particle size.

second metal particles

The constituent material of the second metal particles 31 is different from the constituent material of the first metal particles 21 . It should be noted that the term "constituent material is different" means that, for example, when the alloy composition of the first metal particles 21 is included in the alloy composition range specified in various standards such as the Japanese Industrial Standard, the second metal particles 31 have different alloy compositions. The alloy composition is in a state deviated from this composition range; or on the contrary, when the alloy composition of the second metal particles 31 is included in the alloy composition range specified in various standards such as the Japanese Industrial Standards, the first metal particles 21 The alloy composition is in a state deviated from this composition range. Specifically, for example, when the constituent material of the first metal particles 21 is SUS630, the alloy composition of the constituent material of the second metal particles 31 may deviate from the alloy composition range of SUS630 specified in the Japanese Industrial Standards. In addition, alloys outside the standard can be regarded as different materials when the difference in the content of constituent elements exceeds 3 mass %.

It should be noted that the matrix region 3 may contain other metal particles and ceramic particles made of a material different from that of the second metal particles 31 . The addition amount of these other metal particles and ceramic particles is preferably 50 vol % or less of the second metal particles 31 , more preferably 30 vol % or less, and still more preferably 10 vol % or less.

The average particle diameter of the second metal particles 31 is preferably set to be smaller than the average particle diameter of the first metal particles 21 .

Specifically, the average particle diameter of the second metal particles 31 is preferably 95% or less of the average particle diameter of the first metal particles 21 , more preferably 5% or more and 80% or less, and further preferably 10% or more and 60% or less. As a result, in the composite 1 , the second metal particles 31 having an average particle diameter moderately smaller than the first metal particles 21 surround the secondary particles 2 that are aggregates of the first metal particles 21 . Then, the molded body obtained by injection molding the composite 1 in such a form becomes a sintered body having both the portion derived from the secondary particles 2 and the portion derived from the matrix region 3 when fired. As will be described later, such a sintered body tends to have a structure in which a region with a small average crystal grain size is surrounded by a region with a large average crystal grain size, depending on the size relationship between the particle sizes of the metal particles, and thus achieve both high mechanical strength and high Ductile sintered body. Similarly, a sintered body having both the properties of the constituent material of the first metal particles 21 and the properties of the constituent material of the second metal particles 31 can be obtained.

It should be noted that when the average particle size of the second metal particles 31 is lower than the above lower limit value, although it also depends on the particle size of the first metal particles 21, the second metal particles 31 tend to agglomerate, and therefore in the matrix region 3, it is difficult to disperse the second metal particles 31 uniformly. Therefore, it is difficult for the sintered body to become homogeneous, and there is a possibility that the mechanical strength and ductility may decrease. On the other hand, when the average particle diameter of the second metal particles 31 exceeds the above-mentioned upper limit value, the average particle diameter of the first metal particles 21 is close to the average particle diameter of the second metal particles 31. Therefore, a metal having a smaller average particle diameter is used. There is a possibility that the effect obtained by the sintered body of particles surrounding the sintered body of metal particles having a large average particle diameter, that is, the effect of achieving both high strength and high ductility, is reduced.

It should be noted that when a perfect circle having the same area as the second metal particle 31 is assumed on the cross section of the composite 1, the particle diameter of the second metal particle 31 is obtained as the diameter (equivalent circle diameter) of the perfect circle . In addition, when the circle-equivalent diameter of the arbitrarily selected 10 or more second metal particles 31 is obtained, the average particle diameter is the average value.

In addition, regarding the second metal particles 31, the particle size when the accumulation of the particle size based on mass in the particle size distribution obtained by the laser diffraction method is 10% from the small diameter side is D10, and the particle size when it reaches 50% is set as D10 When D50, the particle size at 90% is defined as D90, (D90-D10)/D50 is preferably 0.5 or more and 5 or less, and more preferably 1.0 or more and 3.5 or less. The second metal particles 31 satisfying such conditions can achieve both the mechanical strength and the ductility of the finally obtained sintered body.

Such second metal particles 31 may be produced by any method. For example, atomization methods (water atomization method, gas atomization method, high-speed rotating water atomization method, etc.), reduction method, carbonyl method, and pulverization method can be used. Metal particles produced by other methods.

Among them, metal particles produced by an atomization method are preferably used as the second metal particles 31 . According to the atomization method, the difference in particle size is small, and a metal powder with a uniform particle size can be obtained. Therefore, by using such second metal particles 31 , stable secondary particles 2 are realized, and the secondary particles 2 in the composite 1 serve as good frameworks. Therefore, the molded body obtained by molding the composite 1 is excellent in shape retention, and the dimensional accuracy of the sintered body can be improved. That is, it contributes to the realization of a sintered body having improved mechanical strength while having a plurality of different properties.

It should be noted that the content of the second metal particles 31 in the matrix region 3 is not particularly limited, but is preferably 50 vol % or more and 90 vol % or less, more preferably 55 vol % or more and 85 vol % or less, and further preferably 60 vol % % or more and 80 volume % or less. By setting the content of the second metal particles 31 within the above-mentioned range, the composite 1 in which poor filling and excessive shrinkage are suppressed can be obtained.

adhesive

The binder 32 binds the second metal particles 31 to each other (similarly to other metal particles and ceramic particles), thereby facilitating maintenance of the shape of the matrix region 3 . The binder 32 is almost removed in the firing step.

The adhesive 32 is not particularly limited as long as it has binding properties. In addition, it may be the same as or different from the adhesive 22, and examples thereof include polyolefins such as polyethylene, polypropylene, and ethylene-vinyl acetate copolymer, and acrylic acids such as polymethyl methacrylate and polybutyl methacrylate. resin, styrene resin such as polystyrene, polyvinyl chloride, polyvinylidene chloride, polyamide, polyethylene terephthalate, polybutylene terephthalate and other polyester, polyether, Various resins such as polyvinyl alcohol, polyvinylpyrrolidone or their copolymers, waxes, alcohols, higher fatty acids, fatty acid metals, higher fatty acid esters, higher fatty acid amides, nonionic surfactants, silicone-based lubricants etc., use one of them or a mixture of two or more of them.

In addition, as the binder 32, a material containing a hydrocarbon-based polymer and a wax is particularly preferably used.

Here, the hydrocarbon-based polymer refers to a polymer compound mainly composed of carbon atoms and hydrogen atoms, and has a degree of polymerization of about 50 or more (preferably 100 or more). In addition, the thermal decomposition temperature of the hydrocarbon-based polymer is higher than that of the wax.

On the other hand, the wax refers to a saturated chain polymer compound mainly composed of carbon atoms and hydrogen atoms, and has a degree of polymerization of about 50 or less (preferably 30 or less).

By using such a hydrocarbon-based polymer in combination with a wax, the initial shape-retaining properties of the molded body are maintained by the wax, and on the other hand, the behavior of the hydrocarbon-based polymer to be gradually decomposed in a relatively wide temperature range is easily established. Since it is easy to maintain the shape of the compact throughout the process, a sintered compact with particularly high dimensional accuracy can be finally obtained.

hydrocarbon polymer

Examples of the hydrocarbon-based polymer include saturated hydrocarbon-based resins, unsaturated hydrocarbon-based resins, and the like. In addition, it is also classified into a chain-like hydrocarbon-based resin, a cyclic hydrocarbon-based resin, and the like according to the bonding form of carbon atoms.

Examples of such hydrocarbon-based polymers include polyolefins such as polyethylene, polypropylene, polybutene, and polypentene, and polyolefins such as polyethylene-polypropylene copolymers and polyethylene-polybutene copolymers. Polyolefin-based copolymers, polystyrene, etc., are composed of one or more of them.

Among them, the adhesive 32 preferably contains at least one of a polyolefin resin and a polystyrene resin. These hydrocarbon-based polymers have relatively large binding force and relatively high thermal decomposability, and thus tend to maintain the shape of the molded body during degreasing. Therefore, these hydrocarbon-based polymers contribute to rapid degreasing and the resulting improvement in sinterability. As a result, a sintered body with high dimensional accuracy can be obtained.

The weight average molecular weight of the hydrocarbon-based polymer is preferably 10,000 or more and 100,000 or less, and more preferably 20,000 or more and 80,000 or less. By setting the weight-average molecular weight of the hydrocarbon-based polymer within the above-mentioned range, it is possible to provide a molded body with sufficient shape-retaining properties and to perform easy and reliable degreasing. It should be noted that when the weight average molecular weight of the hydrocarbon-based polymer is less than the above lower limit value, there is a possibility that sufficient shape retention properties cannot be imparted to the molded body, and when the above upper limit value is exceeded, the molded body may not be degreased. The decomposability of the hydrocarbon-based polymer may decrease.

The content of the hydrocarbon-based polymer in the binder 32 is preferably 1 mass % or more and 98 mass % or less, more preferably 15 mass % or more and 50 mass % or less, and further preferably 20 mass % or more and 45 mass % or less. By making content of a hydrocarbon type polymer into the said range, the characteristic which a hydrocarbon type polymer has in the binder 32 can be fully expressed as needed. In addition, when content of a hydrocarbon type polymer is less than the said lower limit, there exists a possibility that sufficient shape retention property cannot be provided to a molded object. On the other hand, when the above upper limit value is exceeded, components other than hydrocarbon-based polymers such as waxes become relatively too small, so that it takes a long time to degrease the molded body, and there is a possibility that a large amount of hydrocarbon-based polymers may occur due to a large amount of time. The polymer is decomposed at once to cause defects such as cracks in the molded body.

Note that, as the hydrocarbon-based polymer, a hydrocarbon-based polymer having a thermal decomposition temperature of 300°C or more and 550°C or less is preferably used, and a hydrocarbon-based polymer having a thermal decomposition temperature of 400°C or more and 500°C or less is more preferably used. Such a hydrocarbon-based polymer corresponds to a component that is thermally decomposed in a relatively high temperature range as a binder component, and thus contributes to maintaining the shape of the molded body until the degreasing is completed when the molded body is degreased. As a result, a sintered body with high dimensional accuracy can be finally obtained.

In addition, as the hydrocarbon-based polymer, a hydrocarbon-based polymer having a melting point of 100° C. or higher and 400° C. or lower is preferably used, and a hydrocarbon-based polymer having a melting point of 200° C. or higher and 300° C. or lower is more preferably used.

It should be noted that these thermal decomposition temperatures and melting points were measured with a simultaneous differential thermogravimetric measuring apparatus (TG/DTA) or the like.

wax

The wax contains many crystalline polymers, and its weight average molecular weight is smaller than that of the resin, preferably 5,000 or more, and more preferably 10,000 or more. Therefore, when the molded body is degreased, the wax melts and decomposes in a lower temperature range than the hydrocarbon-based polymer, and forms a flow path when it is released to the outside of the molded body. After that, when the molded body is heated at a higher temperature, the decomposition of the hydrocarbon-based polymer starts this time, and the decomposed product is released to the outside of the molded body through the above-mentioned flow path. When the hydrocarbon-based polymer is removed through the flow path in this way, the decomposition product of the hydrocarbon-based polymer is efficiently discharged to the outside, and breakage of the molded body can be prevented. Thereby, the shape of the compact can be more reliably maintained even during the degreasing process, and finally a sintered compact with high dimensional accuracy can be obtained.

As a wax, a natural wax, a synthetic wax, etc. are mentioned, for example.

Among these, natural waxes include, for example, vegetable waxes such as candelilla wax, carnauba wax, rice bran wax, Japanese wax, and jojoba oil, animal waxes such as beeswax, lanolin, spermaceti, etc. Mineral-based waxes such as montan wax, ozokerite, and ceresin, and petroleum-based waxes such as paraffin wax, microcrystalline wax, and petrolatum, etc., may be used in combination of one or more of them.

In addition, the synthetic wax includes synthetic hydrocarbons such as polyethylene wax, modified waxes such as montan wax derivatives, paraffin derivatives, and microcrystalline wax derivatives, hydrogenated castor oil, and hydrogenated castor oil derivatives. Hydrogenated wax, fatty acid such as 12-hydroxystearic acid, amide such as stearic acid amide, ester such as phthalic anhydride imide, etc., one or more of them can be used in combination .

In the present embodiment, it is particularly preferable to use a petroleum-based wax or a modified product thereof, more preferably to use a paraffin wax, a microcrystalline wax or a derivative thereof, and still more preferably to use a paraffin wax. Since these waxes are excellent in compatibility with hydrocarbon-based polymers, homogeneous adhesive compositions and composites can be prepared. Therefore, it contributes to the final production of a homogeneous sintered body excellent in mechanical properties and dimensional accuracy.

The weight average molecular weight of the wax is preferably 100 or more and 2000 or less, and more preferably 200 or more and 1000 or less. By setting the weight-average molecular weight of the wax within the above-mentioned range, when the composite 1 is degreased, the wax can be melted more reliably in a temperature range lower than that of the hydrocarbon-based polymer, and the molded body can be more reliably melted. A flow path for discharging the decomposition product of the hydrocarbon-based polymer is formed on the upper part. In addition, when the weight average molecular weight of a wax is less than the said lower limit, there exists a possibility that the shape retention property of a molded object may fall. On the other hand, when the above upper limit value is exceeded, the temperature range where the wax melts is close to the temperature range where the hydrocarbon-based polymer melts, and cracks or the like may occur in the molded body.

In addition, the content of the wax in the binder 32 is preferably 1 mass % or more and 70 mass % or less, more preferably 10 mass % or more and 50 mass % or less, and further preferably 15 mass % or more and 40 mass % or less. By setting the content of the wax to be within the above-mentioned range, the adhesive 32 can sufficiently and sufficiently express the characteristics of the wax. In addition, when the content of wax is less than the said lower limit, a sufficient quantity of flow paths cannot be formed in a molded object, and cracks etc. may arise when a molded object is degreased. On the other hand, when the above-mentioned upper limit value is exceeded, the proportion of the hydrocarbon-based polymer relatively decreases, and thus there is a possibility that the shape-retaining property of the molded body may decrease.

Moreover, as a wax, it is preferable to use the wax whose melting|fusing point is 30 degreeC or more and 200 degrees C or less, and it is more preferable to use the wax whose melting point is 50 degreeC or more and 150 degrees C or less.

It should be noted that these thermal decomposition temperatures and melting points were measured with a simultaneous differential thermogravimetric measuring apparatus (TG/DTA) or the like.

Although the hydrocarbon-based polymer and the wax have been described above, from another viewpoint, it is preferable that the binder 32 contains both a crystalline resin such as wax and an amorphous resin such as polystyrene. Thereby, the initial shape retention property of the molded body is maintained by the crystalline resin, while the amorphous resin is gradually decomposed in a relatively wide temperature range and discharged to the outside. As a result, a sintered body with particularly high dimensional accuracy can be finally obtained.

The mixing ratio of the crystalline resin and the non-crystalline resin is not particularly limited, but it is preferable to make the non-crystalline resin more than the crystalline resin. Specifically, it is preferable to set the non-crystalline resin to 101 parts by mass with respect to 100 parts by mass of the crystalline resin. 300 mass parts or less, More preferably, it is 110 mass parts or more and 250 mass parts or less. Thereby, the shape-retaining property of a molded object can be improved further, and dimensional accuracy can be further improved finally. That is, when the mixing ratio of the amorphous resin is lower than the above lower limit value, the shape-retaining properties of the molded body at the time of temperature change may be slightly reduced depending on the particle size of the metal powder, the composition of the binder 32 , and the like. On the other hand, when the mixing ratio of the amorphous resin exceeds the above upper limit value, the initial shape retention of the molded body may be slightly reduced depending on the particle size of the metal powder, the composition of the binder 32 , and the like.

Cyclic ether group-containing copolymer

In addition, the cyclic ether group-containing copolymer may be added to the binder 32 as needed. The cyclic ether group-containing copolymer is a copolymer obtained by copolymerizing a monomer containing a cyclic ether group and a monomer copolymerizable with the monomer. By adding such a copolymer, the structure derived from the cyclic ether group-containing monomer has excellent adhesion to the metal powder. On the other hand, the copolymer can improve adhesion with hydrocarbon-based polymers and waxes. compatibility. That is, such a copolymer contributes to improving the mutual wettability of the metal powder, the hydrocarbon resin and the wax, and further contributes to improving the mutual dispersibility in the composite 1 . As a result, such a composite 1 becomes homogeneous, which leads to obtaining a sintered body with high mechanical properties and dimensional accuracy.

As a cyclic ether group, an epoxy group, an oxetanyl group, etc. are mentioned, for example. They are ring-opened by the heat applied to the composite 1, and bond with the hydroxyl groups on the surface of the metal powder. As a result, the metal powder and the copolymer exhibit high adhesion, and the dispersibility of the second metal particles 31 in the matrix region 3 becomes more favorable. In addition, an epoxy group is also particularly preferable among the cyclic ether groups from the viewpoint of being easy to bond with the surface of the metal powder and the like.

In addition, examples of the monomer containing a cyclic ether group include glycidyl acrylates such as glycidyl acrylate and glycidyl methacrylate, and glycidyl esters such as vinyl glycidyl ether and allyl glycidyl ether. Glyceryl ethers, oxetane esters such as oxetanyl acrylate and oxetanyl methacrylate, etc., can be used alone or in combination of two or more.

On the other hand, as a monomer which can be copolymerized with such a monomer, for example, (methyl) such as methyl (meth)acrylate, ethyl (meth)acrylate, and butyl (meth)acrylate can be mentioned. Acrylate-based monomers, olefin-based monomers such as ethylene, propylene, isobutylene, and butadiene, vinyl acetate-based monomers, and the like, can be used in combination of one or more of them. In addition, the expression like (meth)acrylic acid means either acrylic acid or methacrylic acid.

Among them, vinyl monomers and vinyl acetate monomers are preferably used. Ethylene and vinyl acetate have particularly excellent compatibility with hydrocarbon-based polymers and waxes. Therefore, by using both the ethylene monomer and the vinyl acetate monomer, the polymer is interposed between the metal powder, the hydrocarbon-based polymer, and the wax, and the mutual wettability is particularly enhanced.

In addition, as a preferable combination of the monomer containing a cyclic ether group as mentioned above and the monomer which can be copolymerized with the monomer, for example, glycidyl (meth)acrylate (GMA) and vinyl acetate can be mentioned. (VA), glycidyl (meth)acrylate and ethylene, glycidyl (meth)acrylate, vinyl acetate and ethylene (E), glycidyl (meth)acrylate, vinyl acetate and methyl acrylate ( MA), etc.

The content of the cyclic ether group-containing monomer in the cyclic ether group-containing copolymer is not particularly limited, but is preferably 0.1% by mass or more and 50% by mass or less, and more preferably 1% by mass or more and 30% by mass or less. . Thereby, since the adhesiveness between the cyclic ether group-containing copolymer and the second metal particles 31 can be reliably obtained, the above-mentioned effects when the copolymer is used can be more reliably exhibited.

The weight average molecular weight of the cyclic ether group-containing copolymer is preferably 10,000 or more and 400,000 or less, and more preferably 30,000 or more and 300,000 or less. By setting the weight average molecular weight of the cyclic ether group-containing copolymer to be within the above-mentioned range, the fluidity of the composite 1 and the molded body can be balanced while preventing the thermal decomposition property of the cyclic ether group-containing copolymer from being significantly reduced. shape retention.

In addition, the arrangement of the monomers in the cyclic ether group-containing copolymer is not particularly limited, and may be any arrangement such as random copolymerization, alternating copolymerization, block copolymerization, and graft copolymerization.

In addition, the content of the cyclic ether group-containing copolymer in the compound 1 is preferably 10% or more and 100% or less of the wax content, more preferably 15% or more and 80% or less, and further preferably 20% by mass ratio. More than 50% or less. By setting the content of the cyclic ether group-containing copolymer within the above-mentioned range, the mutual wettability of the metal powder, the hydrocarbon-based polymer, and the wax can be particularly improved. As a result, the dispersibility of the second metal particles 31 in the composite 1 is particularly improved.

Further, as the cyclic ether group-containing copolymer, a copolymer having a melting point of 30°C or more and 150°C or less is preferably used, and a copolymer having a melting point of 50°C or more and 100°C or less is more preferably used.

In addition, the adhesive 32 may contain other components. Preferably, the content of other components in the binder 32 is, for example, 10% by mass or less.

The content of the binder 32 in the matrix region 3 is not particularly limited, but is set to be higher than the content of the binder 22 in the secondary particles 2, preferably 1.1 volume times or more and 20 volume times or less, More preferably, it is about 2 volume times or more and 10 volume times or less. By setting the content of the binder 32 within the above-mentioned range, the fluidity required as the composite 1 for metal powder injection molding can be ensured, and on the other hand, the secondary particles 2 can suppress the Compound 1 with the content rate. Such a composite 1 also suppresses poor filling and shrinkage, and thus contributes to the realization of a sintered body with high dimensional accuracy and high mechanical strength.

In addition, when the content rate of the binder 32 is less than the said lower limit, there exists a possibility that the fluidity|liquidity may become inadequate depending on the composition etc. of the binder 32. On the other hand, when the content rate of the binder 32 exceeds the above-mentioned upper limit value, depending on the composition of the binder 32, etc., the shape retention of the molded body may be lowered, the shrinkage rate may be increased, and the dimensional accuracy of the sintered body may be deteriorated. reduce.

The content of the binder 32 in the matrix region 3 is not particularly limited, but is preferably 10 vol% or more and 50 vol% or less, more preferably 15 vol% or more and 45 vol% or less, still more preferably 20 vol% or more and 40 vol% %the following.

It should be noted that the content of the binder 32 in the matrix region 3 can be obtained, for example, by observing the cross section of the matrix region 3 and from the area ratio of the binder 32 in the cross section.

In addition, components other than the second metal particles 31 and the binder 32 , for example, various additives such as a solvent (dispersion medium), a rust inhibitor, an antioxidant, a dispersant, and an antifoaming agent may be added to the matrix region 3 . The addition amount of these additives is preferably about 5 mass % or less of the matrix region 3 , and more preferably about 3 mass % or less.

Manufacturing method of composite for metal powder injection molding

Next, an example of the manufacturing method of the compound for metal powder injection molding is demonstrated.

[1] First, the first metal particles 21 are granulated by various granulation methods.

As a granulation method, a spray drying (spray drying) method, a rotary granulation method, a fluidized bed granulation method, a rotary fluidization granulation method, etc. are mentioned, for example.

For example, in the spray drying method, a slurry (suspension) obtained by mixing the first metal particles 21 and the binder 22 is used. And the secondary particle 2 was obtained by spray-drying this slurry.

In addition, in the slurry, for example, water, alcohols, etc. are used as a solvent (dispersion medium).

In addition, vibration treatment, pulverization treatment, etc. may be applied to the obtained secondary particles 2 as necessary.

Moreover, you may apply heat processing to the obtained secondary particle 2 as needed. Thereby, since the hygroscopicity of the binder 22 is slightly lowered, the secondary particles 2 are less likely to absorb moisture, and the occurrence of sintering defects accompanying the moisture absorption is suppressed.

Furthermore, depending on the conditions of the heat treatment, a sintering phenomenon may occur between some of the first metal particles 21 to cause adhesion (Japanese expression: fixation).

As a heating method, heating with a heating furnace, flame irradiation, laser irradiation, plasma irradiation, etc. are mentioned, for example.

Although the heating temperature varies depending on the composition of the first metal particles 21 and the binder 22, etc., the heating temperature is preferably 200°C or higher and about 800°C or lower, more preferably 250°C or higher and 700°C or lower, and even more preferably 300°C or higher. Below 600℃. By heating at such a temperature, it is possible to suppress the complete sintering of the first metal particles 21 , while locally sintering the first metal particles 21 to each other, thereby reducing the volume (weight) of the binder 22 . As a result, since the secondary particles 2 themselves are not easily deformed, the shape of the composite 1 is easily maintained, and the effects of the secondary particles 2 described above are more reliably exhibited.

The heating time is set according to the heating temperature. The duration of the heating time is preferably 5 minutes or more and 300 minutes or less, more preferably 10 minutes or more and 180 minutes or less, and even more preferably 30 minutes or more and 120 minutes or less. . By setting such a heating time, it is possible to suppress the complete sintering of the first metal particles 21 while locally sintering the first metal particles 21 to reduce the volume of the binder 22 .

In addition, although it does not specifically limit as a heating atmosphere, For example, an oxidizing atmosphere like air and oxygen, an inert atmosphere like nitrogen and argon, a reducing atmosphere like hydrogen, etc. are used. Among them, when oxidation of the first metal particles 21 and the like are considered, an inert atmosphere or a reducing atmosphere is preferably used, and when safety, hydrogen embrittlement, and the like are considered, an inert atmosphere is preferably used.

[2] Next, the second metal particles 31 and the binder 32 are kneaded to obtain a kneaded product.

For the kneading, various kneaders such as a pressurized or double-arm kneader, a roll kneader, a Banbury (registered trademark) type kneader, and a single-screw or twin-screw extruder can be used.

The kneading conditions vary depending on the particle diameter of the second metal particles 31 used, the mixing ratio of the second metal particles 31 and the binder 32, and other conditions. As an example, the kneading temperature can be set to 50°C. The kneading time is set to be 15 minutes or more and 210 minutes or less.

Next, the secondary particles 2 are added to the obtained kneaded product and kneaded again. Thereby, the secondary particles 2 are dispersed in the kneaded material. As a result, the composite 1 having the secondary particles 2 and the matrix region 3 is obtained.

It should be noted that the secondary particles 2 may be added simultaneously with the second metal particles 31 , or conversely, the second metal particles 31 may be added after the secondary particles 2 and the binder 32 are kneaded.

In addition, the above-mentioned production method is an example, and the composite 1 may be produced by a method different from the above-mentioned production method.

Manufacturing method of sintered body

Next, an example of a method of producing a sintered body using the composite 1 will be described.

The method for producing a sintered body includes an injection molding step of injection molding the composite 1 into a desired shape, a degreasing step of degreasing the obtained molded body, and a firing step of firing the obtained degreased body.

That is, the method for producing a sintered body includes a step of injecting the composite 1 into a molding die to obtain a molded body, and a step of degreasing and firing the molded body to obtain a sintered body.

According to such a production method, a sintered body having both high mechanical strength and high ductility can be produced.

Hereinafter, each step will be described in order.

Injection molding process

First, injection molding is performed using the compound 1 as described above. Thereby, a molded body of a desired shape and size (an embodiment of the metal powder molded body of the present invention) is produced.

It should be noted that the composite 1 may also be subjected to a granulation treatment as necessary before molding. The granulation treatment is a treatment of pulverizing the composite 1 using a pulverizing device such as a granulator (Pelletizer (registered trademark)). The average particle diameter of the thus obtained pellets is about 1 mm or more and 10 mm or less.

Next, the obtained pellets are put into an injection molding machine and injected into a molding die for molding. In this way, a molded body in which the shape of the molding die is transferred is obtained.

It should be noted that the shape and size of the produced molded body is determined by estimating the shrinkage amount of the subsequent degreasing and sintering.

Further, if necessary, post-processing such as machining and laser processing may be performed on the obtained molded body.

In addition, the compound 1 may be molded together with another compound different from the compound 1 (two-color molding), or the compound 1 may be injection-molded by prearranging other components in the cavity of the molding die and in contact with them (insert molding). .

Degreasing process

Next, the obtained molded body is subjected to a degreasing treatment (binder removal treatment). In this way, the binder 22 and the binder 32 contained in the molded body are removed (degreased) to obtain a degreased body.

This degreasing treatment is not particularly limited, but in a non-oxidizing atmosphere, for example, in a vacuum or reduced pressure state (for example, 1×10 ^-6 Torr or more and 1×10 ^-1 Torr or less (1.33×10 ^-4 Pa or more and 13.3 Pa or less) ) or by heat treatment in a gas such as nitrogen or argon.

The treatment temperature in the degreasing step is not particularly limited, but is preferably 100°C or higher and 750°C or lower, and more preferably 150°C or higher and 700°C or lower.

In addition, the treatment time in the degreasing step is preferably 0.5 hours or more and 20 hours or less, and more preferably 1 hour or more and 10 hours or less.

In addition, degreasing by such heat treatment may be carried out in a plurality of stages for various purposes (for example, the purpose of shortening the degreasing time). In this case, for example, a method of degreasing at a low temperature in the first half and a high temperature in the second half, and a method of repeating low temperature and high temperature, etc. are mentioned.

In addition, after performing the above-mentioned degreasing treatment, various post-processing may be performed on the obtained degreased body for the purpose of, for example, deburring, formation of microstructures such as grooves, and the like.

It should be noted that the binder 22 and the binder 32 may not be completely removed from the molded body during the degreasing process, and may remain partially, for example, when the degreasing process is completed.

Firing process

Next, the degreased body subjected to the degreasing treatment is fired. Thereby, the degreased body is sintered to obtain a sintered body.

The firing conditions are not particularly limited, but in a non-oxidizing atmosphere, for example, in a vacuum or reduced pressure state (for example, 1 × 10 ^-6 Torr or more and 1 × 10 ^-2 Torr or less (1.33 × 10 ^-4 Pa or more and 133 Pa or less)) Alternatively, it can be performed by heat treatment in an inert gas such as nitrogen or argon. Thereby, the metal powder can be prevented from being oxidized.

The firing step may be performed in two or more stages. Thereby, the efficiency of sintering is improved, and the sintering can be performed in a shorter sintering time.

In addition, the firing step may be performed continuously with the degreasing step described above. As a result, the degreasing step can also be used as a pre-sintering step, the degreased body can be preheated, and the degreased body can be sintered more reliably.

The firing temperature is appropriately set according to the constituent materials of the first metal particles 21 and the second metal particles 31. For example, in the case of Fe-based alloys, it is preferably 1000°C or higher and 1400°C or lower, and more preferably 1050°C or higher and 1350°C or lower.

In addition, the firing time is preferably 0.5 hours or more and 20 hours or less, and more preferably 1 hour or more and 15 hours or less.

In addition, such a calcination process may be divided into a plurality of processes (stages) for various purposes (for example, the purpose of shortening the calcination time, etc.). In this case, for example, a method of firing at a low temperature in the first half and a high temperature in the second half, a method of repeating a low temperature and a high temperature, and the like are exemplified.

In addition, after the above-mentioned firing step, machining, electrical discharge machining, laser machining, etching, etc. may be performed on the obtained sintered body for the purpose of, for example, deburring, formation of microstructures such as grooves, and the like.

In addition, HIP treatment (hot isostatic pressing treatment) and the like may be performed on the obtained sintered body as necessary. Thereby, further densification of the sintered body can be achieved.

Sintered body

Next, embodiments of the sintered body of the present invention will be described.

3 is a cross-sectional view showing an embodiment of the sintered body of the present invention.

The sintered body 100 shown in FIG. 3 has a first portion 110 including a sintered body of the first metal particles 21 , and a second portion 120 including a sintered body of the second metal particles 31 .

That is, the sintered body 100 has a first portion 110 including a sintered body of the first metal particles 21 , and a second portion 120 including a sintered body of the second metal particles 31 , and the constituent material is different from that of the first portion 110 . In such a sintered body 100, a plurality of properties that are difficult to coexist with a single constituent material can be coexisted.

Hereinafter, each part will be described in detail in order.

The first portion 110 includes a sinter of the first metal particles 21 . Such a first portion 110 includes a crystal structure 111 derived from the first metal particles 21 as shown in FIG. 3 .

In addition, the first portion 110 has a strong tendency to inherit the particle shape of the secondary particles 2, and thus becomes a particle-shaped region. Therefore, like the secondary particles 2 in the composite 1, the first part 110 is present in the matrix of the second part 120 in a dispersed (dispersed) manner.

On the other hand, the second portion 120 includes a sintered body of the second metal particles 31 . Such a second portion 120 includes a crystal structure 121 derived from the second metal particles 31 as shown in FIG. 3 .

In addition, since the second portion 120 has a strong tendency to inherit the shape of the matrix region 3 , it becomes a region that surrounds the first portion 110 .

Here, the constituent material of the first portion 110 and the constituent material of the second portion 120 are different from each other. Therefore, the sintered body 100 has both the properties of the constituent material of the first portion 110 and the properties of the constituent material of the second portion 120 .

On the other hand, although the average crystal grain size of the crystal structure 121 may be larger than the average crystal grain size of the crystal structure 111, it is preferably smaller than that. As a result, in the sintered body 100 , the second portion 120 including the crystal structure 121 having a relatively small particle size is formed to expand so as to surround (enclose) the first portion 110 including the crystal structure 111 having a relatively large particle size. In other words, the second portion 120 expands like a net (network), while the first portion 110 is distributed in such a way as to enter its mesh. In such a structure, it is considered that high mechanical strength is obtained mainly by the second portion 120 , and high ductility is mainly obtained by the first portion 110 . Therefore, when stress is generated in the sintered body 100 , it is assumed that the network structure of the second portion 120 expands and contracts and is less likely to be broken. On the other hand, the stress concentration is alleviated by the first portion 110 having high ductility. Therefore, by balancing them, the sintered body 100 can have both high mechanical strength and high ductility.

In this case, when the average crystal grain size of the crystal structure 111 is set to 1, the average crystal grain size of the crystal structure 121 may be less than 1, but it is preferably 0.005 or more and 0.9 or less, and more preferably 0.01 or more. 0.5 or less, more preferably 0.03 or more and 0.3 or less. By forming such a difference in grain size between the crystal structure 111 and the crystal structure 121 , it is easy to maintain a balance of mechanical strength between the first portion 110 and the second portion 120 , so that the mechanical strength of the entire sintered body 100 is difficult to decrease. Specifically, high rigidity mainly brought about by the crystalline structure 121 in the second part 120 and high ductility brought about by the crystalline structure 111 mainly in the first part 110 coexist with a high balance. That is, when the crystal grain size is small, the existence ratio of crystal grain boundaries (crystal grain boundaries) is high, so that the rigidity tends to be high. On the other hand, when the crystal grain size is large, dislocation within the crystal tends to occur, and therefore, the ductility tends to increase. As a result, a sintered body 100 having high mechanical strength and high ductility can be obtained.

In addition, by distributing the first portion 110 and the second portion 120 as described above, the mechanical strength can be further improved, for example, compared to the case where the entire sintered body 100 is occupied by the first portion 110 or the second portion 120 .

It should be noted that the average crystal grain size of the crystal structure 111 shows a tendency to mainly depend on the grain size of the first metal particles 21 , and the average crystal grain size of the crystal structure 121 shows a tendency to mainly depend on the grain size of the second metal particles 31 . . For example, when the particle diameters of the first metal particles 21 and the second metal particles 31 are increased, the particle diameters of the crystal structure 111 and the crystal structure 121 tend to increase accordingly. Therefore, the ratio of the average crystal grain size of the crystal structure 121 to the average crystal grain size of the crystal structure 111 can be adjusted by appropriately changing the particle sizes of the first metal particles 21 and the second metal particles 31 for producing the sintered body 100 .

The average crystal grain size of the crystal structure 111 is not particularly limited, but is preferably about 1 μm or more and about 30 μm or less, and more preferably about 3 μm or more and 25 μm or less. Thereby, necessary and sufficient ductility is imparted to the first portion 110 .

The average crystal grain size of the crystal structure 121 is not particularly limited, but is preferably about 0.05 μm or more and 20 μm or less, and more preferably about 0.1 μm or more and 10 μm or less. Thereby, necessary and sufficient mechanical strength is imparted to the second portion 120 .

In addition, the average crystal grain size of the crystal structure 111 and the average crystal grain size of the crystal structure 121 are obtained by, for example, crystal analysis using an electron beam backscatter diffraction analyzer, respectively. In addition, when calculating an average value, 10 or more pieces of data are used.

The ratio of the first portion 110 to the second portion 120 is not particularly limited, but is preferably 0.01 or more and 100 or less, more preferably 0.1 or more and 70 or less, and further preferably more than 1 and 50 or less. As a result, the balance between the first portion 110 and the second portion 120 is further optimized, so that the sintered body 100 can be obtained without burying their respective characteristics and coexisting.

In addition, the existence ratio was calculated|required by calculating the ratio of the area occupied by the first part 110 to the area occupied by the second part 120 in the cross section of the sintered body 100 .

In addition, the boundary between the first portion 110 and the second portion 120 may be determined based on, for example, the distribution state of the composition. Therefore, for example, the type (crystal structure) of each crystal structure can be determined by crystal analysis using an electron beam backscatter diffraction analyzer, and the boundary can be determined based on the crystal structure.

The shape of the first portion 110 is preferably granular as described above, and from the viewpoint of the aspect ratio, the average value of the major axis/minor axis is preferably 1 or more and 3 or less, more preferably 1 or more and 2.5 or less, and still more preferably 1 or more and 2 the following. The first portion 110 having such an aspect ratio is highly isotropic in its shape, and thus it is difficult to break or the like. For this reason, the first portions 110 can be stably distributed without reducing the mechanical strength of the sintered body 100 , and it is possible to realize the sintered body 100 that can sufficiently exhibit a plurality of different properties.

It should be noted that, for example, crystal analysis is performed on the cross section of the sintered body 100 using an electron beam backscatter diffraction analyzer, and the maximum length of the first portion 110 is obtained from the obtained crystal analysis image (crystal grain map (crystal grain)). The aspect ratio of the first portion 110 is calculated by the (long axis) and the maximum length (short axis) in the direction orthogonal thereto. In addition, when calculating an average value, 10 or more pieces of data are used.

In this case, the average diameter of the first portion 110 is preferably 1.5 times or more and 100 times or less the average crystal grain size of the crystal structure 111 , more preferably 2 times or more and 80 times or less, and still more preferably 3 times or more and 50 times or less. times or less. As a result, the size of the first portion 110 can be optimized with respect to the particle size of the crystal structure 111, and a sintered body 100 having a plurality of different characteristics at a higher level can be obtained.

It should be noted that, for example, crystal analysis is performed on the cross section of the sintered body 100 using an electron beam backscatter diffraction analyzer, and the maximum length (major axis) of the first portion 110 is obtained from the obtained crystal analysis image (crystal grain diagram). Thereby, the average diameter of the first portion 110 is calculated. In addition, when calculating an average value, 10 or more pieces of data are used.

In addition, the sintered body 100 may include portions other than the first portion 110 and the second portion 120 .

Here, as described above, the sintered body 100 has both the properties of the constituent material of the first portion 110 and the properties of the constituent material of the second portion 120 .

On the other hand, the second portion 120 expands so as to surround the first portion 110 . Therefore, even if stress is generated in the sintered body 100, the network structure of the second portion 120 expands and contracts, so that it is difficult to be broken, and the sintered body 100 with high mechanical strength can be obtained.

Therefore, the sintered body 100 does not incur a significant reduction in mechanical strength, and a plurality of different characteristics derived from the first part 110 and the second part 120 can coexist.

For example, stainless steel includes ferritic stainless steel, austenitic stainless steel, martensitic stainless steel, precipitation hardening stainless steel, and austenitic-ferritic stainless steel, and the physical properties are different.

Therefore, for example, a combination of using relatively high-strength precipitation-hardening stainless steel particles as the first metal particles 21 and using relatively high corrosion-resistant austenitic stainless steel particles as the second metal particles 31 is exemplified. Thereby, a sintered body having both high strength due to the sintered body of the first metal particles 21 (the first part 110 ) and high corrosion resistance due to the sintered body of the second metal particles 31 (the second part 120 ) can be obtained 100.

On the other hand, for example, a combination of relatively high ductility ferritic stainless steel particles as the first metal particles 21 and relatively high strength precipitation hardening stainless steel particles as the second metal particles 31 may be used. As a result, a sintered body 100 having both high ductility due to the sintered body of the first metal particles 21 (the first portion 110 ) and high strength due to the sintered body of the second metal particles 31 (the second portion 120 ) can be obtained. .

In addition, regarding combinations other than stainless steel, various properties can be coexisted.

For example, a combination of using relatively low specific gravity titanium alloy particles as the first metal particles 21 and using relatively high strength precipitation hardening stainless steel particles as the second metal particles 31 is exemplified. Thereby, the sintered body 100 which has both weight reduction and high strength can be obtained.

In addition, for example, a combination of using relatively high-strength austenitic stainless steel particles as the first metal particles 21 and using relatively high thermal conductivity copper alloy particles as the second metal particles 31 can be used. Thereby, the sintered body 100 having both high strength and high thermal conductivity can be obtained.

In addition, for example, a combination of using particles of relatively high-strength precipitation-hardening stainless steel as the first metal particles 21 and particles of soft magnetic pure iron as the second metal particles 31 is exemplified. Thereby, a sintered body 100 having both high strength and soft magnetic properties can be obtained.

It should be noted that the combination of materials is not limited to the above-mentioned examples, and any combination may be used.

In addition, the properties to be combined are not limited to the above-mentioned combinations of strength and corrosion resistance, strength and ductility, strength and specific gravity, strength and thermal conductivity, and strength and magnetic properties, and may be any combination of properties.

In addition, although the first part 110 is surrounded by the second part 120 in principle, a part of the surface of the first part 110 may be exposed to the surface of the sintered body 100 .

In addition, the second portion 120 occupies most of the surface of the sintered body 100 in principle. Therefore, in order to enhance the properties required on the surface of the sintered body 100 such as corrosion resistance and high thermal conductivity, a material having these properties may be used as the material of the second metal particles 31 .

Metal powder molded body

Next, embodiments of the metal powder compact of the present invention will be described.

The metal powder formed body (hereinafter also abbreviated as "formed body") according to the present embodiment is a formed body produced by press molding.

4 is a cross-sectional view showing an embodiment of the metal powder compact of the present invention, and FIG. 5 is an enlarged view of a portion B in FIG. 4 . It should be noted that, in FIGS. 4 and 5 , the same reference numerals are attached to the same components as those of the above-described FIGS. 1 and 2 . In addition, about the same structure as FIG. 1, FIG. 2, description is abbreviate|omitted here.

The formed body 5 (an embodiment of the metal powder formed body of the present invention) shown in FIGS. 4 and 5 has: the secondary particles 2 in which the first metal particles 21 are bonded to each other; and the matrix region 3 including the second metal The particles 31 , the binder 32 , and the second metal particles 31 have different constituent materials from those of the first metal particles 21 . Such a molded body 5 can be fired in the same manner as the composite 1, and a sintered body 100 in which a plurality of properties that are difficult to coexist with a single constituent material can be realized can be realized. That is, such a molded body 5 can produce a sintered body 100 having a plurality of different properties.

It should be noted that, in the composite 1 described above, as shown in FIG. 2 , the binder 32 is distributed so as to substantially fill the gaps between the second metal particles 31 to constitute the matrix region 3 . On the other hand, in the matrix region 3 of the compact 5, as shown in FIG. That is, although the composite 1 and the molded body 5 contain the same constituent elements, their forms (structures) are different from each other.

In the secondary particles 2 shown in FIG. 5 , the first metal particles 21 are bonded to each other via the binder 22 .

On the other hand, in the matrix region 3 shown in FIG. 5 , the second metal particles 31 are bonded to each other via the binder 32 .

In the molded body 5 including the secondary particles 2 and the matrix region 3 , the aggregate of the first metal particles 21 is surrounded by the second metal particles 31 having a smaller average particle diameter than the first metal particles 21 . The formed body 5 of such a form is further fired to become a sintered body. Such a sintered body has many different characteristics as mentioned above.

In addition, in other words, by allowing the particulate secondary particles 2 to exist inside the matrix region 3 , it is easy to maintain the shape retention of the molded body 5 . Therefore, for example, even if the content of the binder 32 in the matrix region 3 is reduced, the deformation of the compact 5 is suppressed, so that the shrinkage of the compact during firing is suppressed, and a sintered compact with high dimensional accuracy can be finally obtained.

The presence ratio of the secondary particles 2 to the matrix region 3 is not particularly limited, but is preferably 0.01 or more and 100 or less, more preferably 0.1 or more and 70 or less, and further preferably more than 1 and 50 or less. As a result, the balance between the secondary particles 2 and the matrix region 3 is further optimized, and a sintered body having high mechanical strength and having a plurality of different properties can be obtained.

In addition, this existence ratio was calculated|required by calculating the ratio of the area occupied by the secondary particle 2 with respect to the area occupied by the matrix region 3 in the cross section of the compact 5 .

secondary particles

The secondary particle 2 shown in FIG. 5 includes a plurality of first metal particles 21 and a binder 22 . It should be noted that the secondary particles 2 shown in FIG. 5 have the same configuration as the secondary particles 2 shown in FIG. 2 , and therefore the description thereof will be omitted below.

stromal area

The matrix region 3 shown in FIG. 5 includes: second metal particles 31 , which are composed of different materials and have a smaller average particle diameter than the first metal particles 21 ; and a binder 32 .

That is, the matrix region 3 is an aggregate of the granulated particles 30 in which the second metal particles 31 are bonded via the binder 32 .

In the molded body 5 having such secondary particles 2 and matrix regions 3 , like the composite 1 , the aggregate of the first metal particles 21 is surrounded by the second metal particles 31 having an average particle diameter smaller than that of the first metal particles 21 . . The formed body 5 of such a form is further fired to become a sintered body. Such a sintered body has high mechanical strength as described above and has a number of different properties.

The adhesive 32 used in the matrix region 3 is not particularly limited as long as it has binding properties, and the components described above as the adhesive 22 are particularly preferably used. Since these have high binding properties, the granulated particles 30 can be efficiently formed even in a relatively small amount. In addition, since the thermal decomposability is also high, it can be decomposed and removed reliably in a short time when degreasing and firing are performed.

The average diameter of the granulated particles 30 is preferably 1.5 times or more and 100 times or less the average particle diameter of the second metal particles 31 , more preferably 2 times or more and 80 times or less, and still more preferably 3 times or more and 50 times or less. Thereby, the balance between the particle diameter of the granulated particles 30 and the particle diameter of the second metal particles 31 is optimized. As a result, the granulated particles 30 themselves are less likely to be deformed, and the shape retention properties of the molded body obtained by molding the composite 1 can be further improved.

It should be noted that, for example, an observation image of the cross section of the compact 5 is obtained with an electron microscope, and the average diameter of the granulated particles 30 is taken as the diameter of a perfect circle (equivalent circle) having the same area as the cross section of the granulated particles 30 on the image. diameter) to obtain. In addition, when calculating an average value, 10 or more pieces of data are used. In addition, the outline of the granulated particles 30 can be easily recognized by using an element map image as necessary.

In addition, components other than the second metal particles 31 and the binder 32 , for example, various additives such as a solvent (dispersion medium), a rust inhibitor, an antioxidant, a dispersant, and an antifoaming agent may be added to the matrix region 3 . The addition amount of these additives is preferably about 5 mass % or less of the matrix region 3 , and more preferably about 3 mass % or less.

As mentioned above, although this invention was demonstrated based on preferable embodiment, this invention is not limited to these embodiment. For example, two or more secondary particles may be contained in the composite for metal powder injection molding and the metal powder molded body. In addition, two or more types of granulated particles may be contained in the metal powder compact.

Example

Next, specific examples of the present invention will be described.

1. Manufacture of sintered body

Example 1

<1> Production of secondary particles

First, as the first metal particles, a precipitation hardening stainless steel powder (SUS630) having an average particle diameter of 10 μm produced by a water atomization method was prepared.

On the other hand, as a binder, polyvinyl alcohol (manufactured by Kuraray Co., Ltd., PVA-117) was prepared. In addition, ion-exchanged water was prepared as a solvent. It should be noted that the addition amount of the solvent was set to 50 g per 1 g of the adhesive.

Next, polyvinyl alcohol and ion-exchanged water were mixed and cooled to room temperature, thereby preparing a binder solution. It should be noted that the mixing ratio of the binder and the first metal particles is shown in Table 1.

Next, the first metal particles and the binder solution were mixed to prepare a slurry.

Next, the slurry was put into a spray drying apparatus and granulated to obtain secondary particles having an average particle diameter of 75 μm.

<2> Manufacture of compound

First, as second metal particles, austenitic stainless steel powder (SUS316L) having an average particle diameter of 4 μm produced by a water atomization method was prepared.

On the other hand, as a binder, the binder of the composition shown in Table 1 was prepared.

Next, the second metal particles and the binder were mixed and kneaded in a pressure kneader (kneader) under the conditions of 100° C.×60 minutes. The kneading was performed in a nitrogen atmosphere. In addition, the mixing ratio of the binder and the second metal particles is shown in Table 1.

Next, secondary particles were added to the obtained kneaded product, and the kneading was performed again. Thus, a matrix region is formed and a complex is obtained.

Next, the obtained composite was pulverized with a pelletizer (Pelletizer (registered trademark)) to obtain pellets having an average particle diameter of 5 mm.

<3> Production of sintered body

厚度5mm的盘状。Next, using the obtained pellets, molding was performed in an injection molding machine under molding conditions of material temperature: 130° C. and injection pressure: 10.8 MPa (110 kgf/cm ² ). Thus, a formed body was obtained. It should be noted that the shape of the formed body is

Disc-shaped with a thickness of 5mm.

Next, the molded body was subjected to a degreasing treatment under the degreasing conditions of temperature: 500° C., time: 1 hour, and atmosphere: nitrogen (atmospheric pressure). Thus, a defatted body was obtained.

Next, the degreased body was subjected to firing treatment under firing conditions of temperature: 1270° C., time: 3 hours, and atmosphere: nitrogen (atmospheric pressure). Thus, a sintered body was obtained.

Example 2

<1> Production of secondary particles

First, secondary particles were obtained in the same manner as in Example 1.

<2> Production of granulated particles for matrix region

Next, as second metal particles, austenitic stainless steel powder (SUS316L) having an average particle diameter of 4 μm produced by a water atomization method was prepared.

On the other hand, as a binder, polyvinyl alcohol (manufactured by Kuraray Co., Ltd., PVA-117) was prepared. In addition, ion-exchanged water was prepared as a solvent. It should be noted that the addition amount of the solvent was set to 50 g per 1 g of the adhesive.

Next, polyvinyl alcohol and ion-exchanged water were mixed and cooled to room temperature, thereby preparing a binder solution.

Next, the second metal particles and the binder solution were mixed to prepare a slurry.

Next, the slurry was put into a spray drying apparatus and granulated to obtain granulated particles for a matrix region having an average particle diameter of 50 μm.

<3> Production of sintered body

厚度5mm的盘状。Next, after mixing the secondary particles and the granulated particles, they were molded under the following molding conditions to obtain a molded body. It should be noted that the shape of the formed body is

Disc-shaped with a thickness of 5mm.

Forming conditions

Forming method: Press molding

·Forming pressure: 100MPa (1t/cm ² )

Next, the molded body was subjected to a degreasing treatment under the degreasing conditions of temperature: 500° C., time: 1 hour, and atmosphere: nitrogen (atmospheric pressure). Thus, a defatted body was obtained.

Next, the degreased body was subjected to firing treatment under firing conditions of temperature: 1270° C., time: 3 hours, and atmosphere: nitrogen (atmospheric pressure). Thus, a sintered body was obtained.

Example 3

A sintered body was obtained in the same manner as in Example 1, except that the obtained secondary particles were put into a heating furnace and subjected to heat treatment. It should be noted that the conditions of the heat treatment are as follows.

heating conditions

·Heating temperature: 500℃

· Heating time: 60 minutes

· Heating atmosphere: nitrogen atmosphere

Example 4

A sintered body was obtained in the same manner as in Example 2, except that the obtained secondary particles were put into a heating furnace and subjected to heat treatment. It should be noted that the conditions of the heat treatment are as follows.

heating conditions

·Heating temperature: 500℃

· Heating time: 60 minutes

· Heating atmosphere: nitrogen atmosphere

Examples 5 to 21

A sintered body was obtained in the same manner as in Example 1, except that the production conditions were changed as shown in Tables 1 and 2.

Comparative Examples 1 and 3

A sintered body was obtained in the same manner as in Example 1, except that the composite was produced only in the matrix region. It should be noted that the production conditions of the used metal particles and the like are shown in Table 1.

Comparative Examples 2 and 4

A sintered body was obtained in the same manner as in Example 1, except that the formed body was produced by using only the secondary particles. It should be noted that the production conditions of the used metal particles and the like are shown in Table 1.

2. Evaluation of the sintered body

2.1 Average crystal grain size, aspect ratio of the first part and average diameter of the first part

The sintered body obtained in each Example and each Comparative Example was cut, and the cross section was subjected to crystal analysis using an electron beam backscatter diffraction analyzer.

Next, the average crystal grain size of the first portion, the average crystal grain size of the second portion, the average value of the aspect ratio of the first portion, and the average diameter of the first portion were measured, respectively.

The measurement results are shown in Tables 1 and 2.

2.2 Evaluation of tensile strength

The tensile strength of the sintered bodies obtained in the respective Examples and Comparative Examples was measured by the test method specified in JIS Z 2241:2011 using the test pieces specified in ISO 2740:2009.

Here, assuming that the tensile strength of the sintered body obtained in Comparative Example 2 is 1, the tensile strength of the sintered body obtained in each Example and each Comparative Example in which the second metal particles are austenitic stainless steel powder The strength was calculated as a relative value with respect to the tensile strength of the sintered body obtained in this Comparative Example 2.

In addition, the tensile strength of the sintered body obtained in Comparative Example 4 was set to 1, and the tensile strength of the sintered bodies obtained in each of the Examples and Comparative Examples in which the second metal particles were precipitation-hardening stainless steel powder was: The relative value with respect to the tensile strength of the sintered body obtained in this comparative example 4 was calculated.

Next, the calculated relative values were evaluated against the following evaluation criteria.

Tensile Strength Evaluation Criteria

◎: The tensile strength is very large (relative value exceeds 1.1)

○: High tensile strength (relative value exceeds 1 and is 1.1 or less)

△: Low tensile strength (relative value exceeds 0.9 and is 1 or less)

×: The tensile strength is very small (relative value is 0.9 or less)

The evaluation results are shown in Tables 1 and 2.

2.3 Evaluation of elongation

About the sintered body obtained in each Example and each comparative example, the elongation was measured by the test method prescribed|regulated by JIS Z 2241:2011 using the test piece prescribed|regulated by ISO 2740:2009.

Here, the elongation of the sintered body obtained in Comparative Example 2 is set to 1, and the elongation of the sintered body obtained in each of the Examples and Comparative Examples in which the second metal particles are austenitic stainless steel powder The relative value with respect to the elongation of the sintered body obtained in this Comparative Example 2 was calculated.

In addition, the elongation of the sintered body obtained in Comparative Example 4 was set to 1, and the elongation of the sintered body obtained in each of the Examples and Comparative Examples in which the second metal particles were precipitation-hardening stainless steel powder was: The relative value with respect to the elongation of the sintered body obtained in this comparative example 4 was calculated.

Next, the calculated relative values were evaluated against the following evaluation criteria.

Elongation Evaluation Criteria

◎: The elongation is very large (relative value exceeds 1.1)

○: Large elongation (relative value exceeds 1 and is 1.1 or less)

△: Small elongation (relative value exceeds 0.9 and is 1 or less)

×: The elongation is very small (relative value is 0.9 or less)

The evaluation results are shown in Tables 1 and 2.

2.4 Evaluation of corrosion resistance

About the sintered body obtained in each Example and each comparative example, the salt spray test was performed according to the method prescribed|regulated by JIS Z 2371:2015. Specifically, after subjecting each sintered body to a test for 240 hours, the weight increase per unit volume was calculated. It should be noted that the test time was set to 240 hours.

Next, the appearance of the sintered body was visually observed to confirm the presence or absence of rust. Then, relative evaluation was performed with respect to the following evaluation criteria.

Corrosion Resistance Evaluation Criteria

◎: Relatively very little rust

○: Relatively little rust

△: Relatively much rust

×: Relatively much rust

The evaluation results are shown in Tables 1 and 2.

2.5 Evaluation of dimensional accuracy

The dimensions of the sintered bodies obtained in the respective Examples and Comparative Examples were measured.

Next, the deviation between the measured dimension and the design value is calculated. Then, with respect to the deviation (dimensional accuracy) from the design value, relative evaluation was performed with reference to the following evaluation criteria.

Dimensional Accuracy Evaluation Criteria

◎: Relatively high dimensional accuracy

○: Relatively high dimensional accuracy

△: Relatively low dimensional accuracy

×: Dimensional accuracy is relatively very low

The evaluation results are shown in Tables 1 and 2.

Table 1

Table 2

As is apparent from Tables 1 and 2, the sintered bodies obtained in the respective Examples can have a plurality of different properties.

In addition to the examples shown in the table, for Ni-based alloys, Co-based alloys, and Ti-based alloys, sintered bodies were produced in the same manner as above, and all of them were obtained in the same manner as above. A sintered body with multiple material properties.

Claims (9)

1. A composite for metal powder injection molding, characterized in that it has: secondary particles in which the first metal particles are bonded to each other; and a matrix region comprising second metal particles and a binder, wherein the constituent material of the second metal particles is different from the constituent material of the first metal particles, The combination of the constituent materials of the first metal particles and the constituent materials of the second metal particles is: precipitation hardening stainless steel and austenitic stainless steel; ferritic stainless steel and precipitation hardening stainless steel; titanium alloy and precipitation hardening system Stainless steel; austenitic stainless steel and copper alloys; or precipitation hardening stainless steel and pure iron. 2. The composite for metal powder injection molding according to claim 1, characterized in that: The secondary particles are formed by bonding the first metal particles to each other via a binder. 3. The composite for metal powder injection molding according to claim 1 or 2, characterized in that, In the secondary particles, the first metal particles self-adhere to each other. 4. The composite for metal powder injection molding according to claim 1 or 2, characterized in that, The secondary particles are dispersed in the matrix region. 5. The composite for metal powder injection molding according to claim 1 or 2, characterized in that, The average particle diameter of the second metal particles is smaller than the average particle diameter of the first metal particles. 6. A metal powder formed body, characterized in that it has: secondary particles in which the first metal particles are bonded to each other; and a matrix region comprising second metal particles and a binder, wherein the constituent material of the second metal particles is different from the constituent material of the first metal particles, The combination of the constituent materials of the first metal particles and the constituent materials of the second metal particles is: precipitation hardening stainless steel and austenitic stainless steel; ferritic stainless steel and precipitation hardening stainless steel; titanium alloy and precipitation hardening system Stainless steel; austenitic stainless steel and copper alloys; or precipitation hardening stainless steel and pure iron. 7. A method of manufacturing a sintered body, comprising: A step of injecting the metal powder injection molding compound according to any one of claims 1 to 5 into a molding die to obtain a molded body; and A step of firing the compact to obtain a sintered compact. 8. A sintered body, characterized in that it has: a first portion, comprising a sinter of first metal particles; and a second part surrounding the first part and comprising a sinter of second metal particles of a different material from the first metal particles, The combination of the constituent materials of the first metal particles and the constituent materials of the second metal particles is: precipitation hardening stainless steel and austenitic stainless steel; ferritic stainless steel and precipitation hardening stainless steel; titanium alloy and precipitation hardening system Stainless steel; austenitic stainless steel and copper alloys; or precipitation hardening stainless steel and pure iron. 9. The sintered body according to claim 8, wherein The average crystal grain size of the second portion is smaller than the average crystal grain size of the first portion.

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